Process for the production of new synthetic resins from vinyl phenol type polymers

Polymers and copolymers of ortho and meta vinyl phenols and their lower nuclear homologues are reacted with an aldehyde or aldehyde-generating agent, e.g. formaldehyde, butyraldehyde, furfuraldehyde, hexamethylene tetramine and paraformaldehyde to give thermosetting methylol derivatives. Copolymers specified are those with styrene compounds, vinyl naphthalenes, acenaphthalene, N-vinyl carbazole, cyclopentadiene, vinyl esters, acrylic esters, acrolein and allyl compounds. The reaction may take place in solution, e.g. in water, alcohol, ketone or a lower ester, in emulsion, or superficially to give a surface layer, and catalysts, e.g. sodium hydroxide or succinic acid may be present. In a modification, after partial aldehyde condensation the remaining vinyl phenol units may be etherified. In examples: (1) powdered poly m-vinyl phenol was dissolved in aqueous sodium hydroxide and a molecular equivalent of formaldehyde added; (2) m-vinyl phenol-styrene copolymers were (a) treated with succinic acid and paraformaldehyde, (b) case-hardened with aqueous sodium hydroxide and formaldehyde, or (c) heated with hexamethylene tetramine; (3) poly m-vinyl phenol plasticized with dibutyl phthalate was heated with hexamethylene tetramine; (4) m-vinyl phenol-acrylonitrile copolymers were suspended in alcoholic potash solution with acetaldehyde using t-butyl hydroperoxide as a catalyst; (5) m-vinyl phenolmethyl acrylate copolymer in latex form was treated with (a) ammonia and a formaldehyde solution, or (b) made alkaline with sodium hydroxide and a formaldehyde solution added. Fillers, dyestuffs, pigments, and mould lubricants may be incorporated into the products which may be moulded or formed into films. Specifications 691,036, 691,037, 691,038 and 691,040 are referred to.